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Porter-Cable CPL6025 User Manual

Porter-Cable CPL6025
22 pages
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Oillube Single-Stage
Portable Compressor
IMPORTANT
Please make certapn that the person who us to use
thus equipment carefully reads and understands
these mstruchons before sta_ng operations
RtoP_scx_w.Pow_ toOLS
The Model and Sernal No plate IS located on the
frame Record these numbers in the spaces below
and retain for future reference
Model NO
Type
Senal No
Part NO D24938-103-1
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Porter-Cable CPL6025 Specifications

General IconGeneral
Max Pressure150 PSI
Power SourceElectric
Voltage120V
Pump TypeOil-Free
MotorInduction
Amps15 Amps

Summary

SAFETY GUIDELINES - DEFINITIONS

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION (Property Damage)

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

IMPORTANT SAFETY INSTRUCTIONS

RISK OF EXPLOSION OR FIRE

Identifies hazards related to ignition of flammable vapors by compressor sparks and overheating due to blocked ventilation.

RISK OF BURSTING

Details risks associated with air tank weakening from rust, modifications, or vibration, and tool/accessory over-pressurization.

ATTACHMENTS & ACCESSORIES

Warns that exceeding pressure ratings of tools, spray guns, or inflatables can cause them to explode or fly apart.

RISK FROM FLYING OBJECTS

Warns compressed air can cause tissue damage and propel debris at high speeds, causing injury or property damage.

RISK TO BREATHING

Highlights that compressor air is not safe for breathing, and sprayed materials contain harmful vapors.

RISK OF ELECTRICAL SHOCK

Explains that improper use of electricity can cause shock, and repairs by unqualified personnel can be fatal.

RISK FROM MOVING PARTS

Details how moving parts like belts and pulleys can cause serious injury if contacted or if guards are removed.

RISK OF BURNS

Warns that touching hot metal parts like the compressor head or outlet tubes can cause serious burns.

RISK OF FALLING

Highlights the danger of a portable compressor falling from elevated positions, causing injury or death.

RISK OF PROPERTY DAMAGE WHEN TRANSPORTING COMPRESSOR

Covers risks of oil leaks causing fire, breathing hazards, and damage to vehicle surfaces during transport.

DESCRIPTION OF OPERATION

AIR COMPRESSOR COMPONENTS

Details the function of key components like the drain valve, thermal protector, filter, pump, check valve, and safety valve.

PRESSURE CONTROL SYSTEM

Explains the function of the pressure switch, pressure release valve, tank gauge, outlet gauge, and regulator.

INSTALLATION

Items Needed for Assembly

Lists the tools and parts required for the assembly process.

Installing Wheels and Rubber Foot Strip

Step-by-step guide for attaching the wheels and rubber feet to the unit.

Installing Handle

Instructions for attaching the unit's handle, including precautions for stability and lifting.

Location of the Air Compressor

Advises on operating the compressor in a clean, dry, well-ventilated area, avoiding moisture and obstructions.

Lubrication and Oil

Explains the correct type of oil to use, cautions against overfilling, and details the importance of initial oil fill.

Oil Fill Procedure

Details how to add compressor oil to the crankcase, including capacity and when to drain/refill.

Extension Cords

Provides guidelines for using extension cords, emphasizing wire gauge, length, and grounding.

Voltage and Circuit Protection

Refers to parts manual for voltage requirements and circuit protection, stressing correct fuse/breaker ratings.

Piping

Warns against plastic pipe, recommends metal pipe for air distribution, and guides on sizing and installation.

GROUNDING INSTRUCTIONS

RISK OF ELECTRICAL SHOCK!

Explains grounding importance for reducing shock risk and avoiding adapters, with visual guide for 120V models.

Improper Grounding Warning

Cautions against modifying the plug and ensuring proper grounding wire connection.

Additional Regulators and Controls

BREAK-IN PROCEDURES

OPERATING PROCEDURES

Daily Start-Up Checklist

Steps for starting the compressor, including attaching hoses and setting the regulator.

When you are finished

Procedures for shutting down the compressor, including draining the tank and releasing pressure.

MAINTENANCE

Routine Maintenance Schedule

Outlines daily, every 40, 100, 160 hours, and yearly maintenance tasks.

SERVICE INSTRUCTIONS

Air Filter - Inspection and Replacement

Instructions for cleaning and replacing the air filter, emphasizing its importance for performance.

Oil - Checking and Changing

Details daily oil checks and recommended oil changes every 100 hours, including capacity and types.

Check Valve - Inspection and Replacement

Guide for inspecting, cleaning, or replacing the check valve annually or as needed.

Safety Valve - Inspection and Replacement

Emphasizes daily testing of the safety valve for proper operation and replacement if faulty.

Belt - Replacement

Warns about serious injury from moving parts and the need for guards during belt replacement.

BELT MAINTENANCE

Belt Guard - Removal and Installation

Instructions for removing and installing the belt guard, including safety precautions.

Belt Replacement and Tension Adjustment

Steps for replacing the drive belt, including motor tilt, centering, and tension adjustment.

PRESSURE SWITCH AND OVERLOAD PROTECTOR

Pressure Switch - Replacement

Warns against adjusting or defeating the pressure switch and advises using the same rated switch for replacement.

Motor Overload Protector - Reset

Explains how to reset the motor's thermal overload protector by depressing the red button if the motor overheats.

Pulley and Flywheel - Alignment

Servicing Intake and Exhaust Valves

STORAGE

TROUBLESHOOTING GUIDE

Excessive tank pressure safety valve pops off.

Addresses issues with the pressure switch not shutting off the motor or contacts being welded.

Air leaks at fittings.

Guide to tightening loose tube fittings and checking for leaks with soapy water solution.

Air leaks at or inside check valve.

Troubleshooting leaks from a malfunctioning or dirty check valve, advising removal and cleaning/replacement.

Air leaks at pressure switch release valve.

Addresses leaks from the pressure switch release valve due to malfunction, advising removal and replacement.

Air leaks in air tank or at air tank welds.

Instructs to replace the air tank if damaged, warning against modifying it due to explosion risk.

Air leak from safety valve.

Advises operating safety valve manually; if it still leaks, it must be replaced.

Knocking noise

Covers causes like loose pulley/flywheel, low oil, or carbon buildup, with corresponding corrections.

Restricted air intake

Addresses dirty air filters, excessive usage, or incorrect accessories as causes for restricted intake.

Compressor is not supplying enough air to operate accessories.

Covers causes from restricted intake to leaks, recommending filter cleaning, belt adjustment, or larger compressor.

Motor will not run.

Covers motor overload, malfunctioning capacitor/motor, pressure switch issues, loose connections, or tripped breakers.

Paint spray on internal motor parts.

Advise not to operate compressor in spray areas due to potential contamination of internal motor parts.

Excessive belt wear.

Addresses excessive belt wear due to loose or tight belts, loose pulleys, or pulley misalignment.

Squealing sound.

Identifies causes of squealing as loose belts, loose pulleys, or lack of oil, with corresponding corrections.

Pressure reading on the regulated pressure gauge drops when an accessory is used.

Explains that some pressure drop is normal, but excessive drop may require regulator adjustment.

Regulator knob - continuous air leak.

Addresses continuous air leaks from the regulator knob due to dirty or damaged internal parts.

ACCESSORIES

FILTERS, REGULATORS, LUBRICATORS

Describes filters, regulators, and lubricators for air line treatment, pressure control, and oil administration.

PLUMBING COMPONENTS

Details connectors, adapters, and fittings for joining air line components with NPT threads.

HOSE

Discusses 3/8" I.D. hose for high CFM and 1/4" coil hose for lightweight, self-retracting applications.

QUICK-CONNECTS

Explains quick-connect bodies and plugs for easy attachment/separation, advising against mixing styles.

LIMITED WARRANTY

Warranty Coverage

Outlines warranty periods for pumps and other parts, excluding damage from misuse, improper installation, or wear items.

Warranty Exclusions

Lists conditions not covered by warranty, such as cosmetic defects, expendable items, and consequential damages.

Warranty Service

Provides instructions for obtaining warranty service, including contacting authorized centers and retaining proof of purchase.

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